Battery Safety and Design Manual for Payloads

1. Battery Safety and Design Manual for Payloads • presented by • Jerri S. Ling • September 13, 2004

2. Background • Battery community suggests that the JSC battery handbook needs to be updated (June 2001). • RMO submits a Code Q RTOP proposal to update the JSC battery handbook (Sept. 2001). • RTOP is approved Oct. 2002 , however payload community recommendations for updates differ from PSRP recommendations (Jan. 2003 to March 2003). • Decision to make document internal to GRC (March 2003). • Initial information gathering (Best Practices, Lessons Learned, text books, graphics, vendor sites, etc) (March 2003 to Sept. 2003). • GRC-M8100-006 Battery Safety and Design Manual for Payloads completed (July 2004).

3. Overview • DOCUMENT PURPOSE - Provides a compendium of quality and safety-related best practices and reference information for design, and testing of cells and batteries used in space flight applications. • DOCUMENT SCOPE - Intended to provide project managers and design engineers with key elements of battery selection, factors to consider during the design/development phases, and clarification of the safety review process for batteries. • Used by payload designers in conjunction with the JSC Battery Handbook (JSC 20793). • Allows Project Management to more accurately map out required resources based on battery-related tasks that need to be performed.

4. Contents • CHAPTER 2 - REFERENCES • Applicable Documents • NSTS 1700.7B and it’s ISS Addendum - Safety Policy and Requirements for Payloads • NSTS/ISS 13830 - Payload Safety Review and Data Submittal Requirements • JSC 20793 - Manned Space Vehicle Battery Safety Handbook • GRC-0510-002 Space Assurance Requirements and Guidelines (SARG) • Others

5. Contents • CHAPTER 3 - CELL/BATTERY DESIGN CONSIDERATIONS • Charging Batteries • Preventing Battery Short Circuits • Voltage Reversal • Thermal • Preventing Leakage • Preventing Improper Insertion

6. Contents • CHAPTER 4.0 - FACTORS AFFECTING BATTERY PERFORMANCE • Voltage Level • Discharge load • Discharge mode (constant current, constant power, constant load, etc.) • Temperature during discharge • Service Life • Voltage Regulation • Charging Voltage • Battery Age/Storage Conditions • Battery Design

7. Contents • CHAPTER 5.0 - BATTERY SELECTION AND APPLICATIONS • CHAPTER 6.0 - CELL/BATTERY TEST PLANS • Purpose of Test Plan • Test Plan Outline • Test Plan Checklist

8. Contents • CHAPTER 7.0 - GROUND TEST CONSIDERATIONS • Hazards and Precautions for Battery usage • Battery Test Facility Checklist • Safe Handling Requirements • Lead-Acid Batteries • Nickel-Cadmium Batteries • Lithium Batteries • Emergency Procedures • Exposure to Electrolyte • Leakage/Venting/Temperature increase • Cell Rupture • Lithium Cell Fires • Disposal Procedures

9. Contents • CHAPTER 8.0 - FLIGHT SAFETY REQUIREMENTS • Overview of Flight Safety Review Process/Requirements Summary • General Hazards and Controls • Structural • Gas Evolution • Elevated Pressure • Electrolyte Leakage • Short Circuits • Circulating Currents • High Temperature • Overcharging • Safety of Specific Battery Types • Lithium Ion, Nickel-Cadmium, Nickel Hydrogen, Silver-Zinc, et al.

10. Contents • CHAPTER 9.0 - CELL SCREENING TESTS • Automated Testing Equipment • Coulombic Efficiency • Polarization Testing • Open Circuit Decay Test • Tailoring Screening Tests for Specific Cells • Thermal Tests

11. Contents • CHAPTER 10.0 - BATTERY TEST PROGRAM • Engineering/Certification Tests • Battery Level Performance Testing • Abuse Tests • Qualification Testing • Flight Acceptance Testing • Payload vs. GSE Usage and Testing • Recommendations

12. Contents • CHAPTER 11.0 - OTHER ENERGY STORAGE DEVICES • Fuel Cells (description of various types), Flywheels • APPENDIX A - LESSONS LEARNED • APPENDIX B - THEORETICAL VOLTAGE/CAPACITY TABLE • APPENDIX C - SUMMARY OF BATTERY BEST PRACTICES • Glossary of Terms/Acronym List

13. 8100/Risk Management Office Document available from GRC BMS